Shaping Metal with Woodworking Tools

Metal working in the woodshop: A demonstration of creating metal parts from aluminum and brass using tools common to woodworking.
Some of the tools shown in the video:
Freud Diablo 60 tooth sawblade: amzn.to/3o15DhN
IMachinist Bimetal Bandsaw Blades for 14" bandsaw (93.5"):
1/2" 6-10 tpi: amzn.to/2T3ZaUZ
1/2" 10-14 tpi: amzn.to/3o1vm9B
DeWalt 611 router with fixed and plunge base: amzn.to/353lvHK
DeWalt scroll saw: amzn.to/342Aliy
Brass router template bushing set: amzn.to/2H9vgMH
Double-sided carpet tape: amzn.to/31gz0CN
3M double-sided film tape: amzn.to/2Hc6ZFu

[@rashakawa]

@Patrick Sullivan I want to thank you for your channel. I do not have... Well any money and I've found that woodworking is very expressive when looking for tools. I first saw one of your videos 3 days ago (Fri 13 Nov) since then I've made 3 carving tools and they have come out simply fantastic. My next project of yours I'm going to attempt is your disappearing lathe... I knew you could make one using a drill but couldn't find any decent video's about it. Your mini router table I'll be trying to that is if I have everything to do it. But most of all I can't wait to start using the tools I've made and it's literally all thanks to you. I can't thank you enough for putting out this kind of content. Your awesome and please keep making more. (The portman's tool fabrication stuff is the best)

[@matthewrose8976]

I really appreciate you demonstrating your mistakes as well as your successes!

[@romaness2553]

Totally agree with you! 👍

[@frankzuccarini3432]

Your understanding, and ability to have ME understand, are incredible! Thanks so much.............. Frank

[@dinastyrodcustom8408]

Wow,,,,sangat menakjubkan hasilnya,pengerjaannyapun sangat detail...

[@Erik_The_Viking]

Great job! Loved your mistakes too, as they're great to learn from. it's also nice to get rid of the myths around metal working with tools that are typically used for wood. I've used jigsaws on metal, provided you use a metal blade no problems.

[@ivanlitvinov6823]

It's so good to see a new video from you!

[@MiniLuv-1984]

Thanks for the inspiration to take on my own and the tips to reduced the number of mistakes. Cheers!

[@phillipdittmer4808]

When I was doing my apprenticeship, we were only allowed to use a drill press, cold chisel, hack saw, files and emery cloth to make tools from plate steel with a polished surface. You don't need a workshop full of machine tools.

[@vikassm]

Very similar tools during my apprenticeship too. I also had access to a coal furnace/forge, a huge anvil and an almost equally huge sledgehammer. And I was 130lbs :) It was almost 15 years later that I first saw a metal cutting jigsaw!! Obviously I bought 2 of those and many many more power tools later, But I'm confident my work used to be far more satisfying when I was using basic & mostly hand tools.

[@superspecialty5169]

I too started off with the basics, but progressed to using special tools/equipment needed to accomplish the repairs on marine vessels as a marine machinery mechanic of 35yrs. I guess you have carpal tunnel syndrome too?

[@ElRel]

Excellent video as always....and thanks for pushing boundaries.

[@ffff1758]

It's allways a pleasure to look at yor videos Patrick! Regards Carlos

[@zolatanaffa87]

Hello, great video well explained. Years ago I also tried to work aluminum with the router and I saw that with many shallow passes you get to the result, reducing vibrations and slightly less stressing the router's bit. I appreciated your passage where you talk about working very carefully and safely, because it is really easier to get hurt if you are distracted. p.s. half a millimeter per pass I also worked 4mm thick iron plates ... then I threw away the router's tip but I managed!

[@bricknick]

I'm cutting Aluminium nearly every day, up to 10mm thickness. There are two important things not to be missed. 1. choose a blade with teeth arranged in a negative angle. The provide a pulling cut like we say in Germany 2. Cool your blade. There are several lubricants on the market from specalized ones to white spirits. they make a real mess on your tool but the cuts are way better

[@AH900112]

What is your opinion of the new "Pégas Scroll Band Saw"? What is the pros and cons if one wishes to work much in 1cm brass/aluminium but occasionally make small projects in hard woods? Is it nearly impossible to make effortless long straight cuts in wood and soft metals with this scroll band saw you think?

[@MCsCreations]

Really interesting, Patrick! Thanks a lot for all the tips! 😊 Stay safe there with your family! 🖖😊

[@green_building]

You are brilliant as always 😎👍👍✨

[@travislangendoen975]

Awesome video! That quick bit about mdf templates hit home with me. I've been insane overthinking my templating strategy...

[@edualbergaria10]

I love this channel

[@sethbracken]

Excited to see what comes next.

[@robertmccluskey1076]

I purchased a table saw blade designed to cut aluminum and brass. It has 60 carbide teeth that are set at a negative rake. It could be used on a SawStop if the safety mechanism is disengage. I don’t have a SawStop i. It works fine on my Delta contractors saw with a cut off sled. I put a piece of plexiglass over the top to keep the chips down.

[@sajidrafique375]

When cutting Al on tablesaw, it will help to sandwich the thin Al in wood somehow if possible and make it thicker and run into the blade.

[@dolfinmagikpro]

I do this, too, when cutting thin brass and aluminum sheeting on my scroll saw! Works very well!

[@AbuSamiQ]

Thank you for sharing.

[@mpart_woodlathe-stuff]

Very encouraging; I am encouraged by this vid Patrick. Thank you for presenting to us🙏 Stay safe. -Mike😷

[@j.hankinson7803]

Great video. Thanks for posting it. I do prefer using my CNC for most templates and projects though. I’m finding it to be the most versatile tool in my shop.

[@jacksikes4825]

I am not sure if I will ever have need to work with metal as you have in this video, as I struggle to get the results I want with wood much less metal! I will say this though I so enjoy watching your videos, your precision and craftsmanship is inspiring! I think I would even watch you do a video on knitting! Please stay safe and keep making videos!!

[@TrevorDennis100]

I am am not entirely sure about using aluminum on a belt sander, but it is 'probably' OK. One of the most serious offenses you could commit in the machine shop I worked in for 40 years was using brass or aluminum on a bench grinder, because it clogs the wheel, and then comes off in tiny projectiles the next time steel is ground on the same wheel. You mentioned vibration using the router on aluminum, which was ironic because you had just shown how to avoid it. The answer is to use spiral flute cutters so that the cutter is in constant contact with the part. Next best thing is a four flute end mill - you'd obviously need the right size for your collet. You'll need to drill a starter hole when making slots if using an end mill. As I said in another comment, you need some sort of lube with aluminum to prevent swarf sticking to the part and cutting tool.

[@paulyanney3151]

Good information thanks 🙏

[@larsbunch]

Thanks for this video. There are a few aluminum parts I would like to re-make for a camera and this video gives me a bit more hope that I can successfully tackle that part of the job.

[@spencerbass7142]

Great video, very interesting.

[@genericname2284]

What I learned from this video: I will be making the custom parts I need out of MDF lol

[@michaellee8198]

As always, interesting and well presented. Only wish you would contribute more regularly.

[@Yonatan24]

Interesting as always, thanks!

[@danfall8233]

Fantastic content Patrick, really glad I stumbled across your channel! I'm a metal work engineer getting into woodwork so it's interesting seeing things from the other side. Kudos on your metal work though- looks amazing, and owning your mistakes: so refreshing to see. One word of caution: the only thing that made me wince was using the shop vac to clear the swarf (chips)- I'm sure it was fine in your case as the chips probably cooled as you set-up the shot, but if you suck up fresh cut & HOT chips into the same vac as your sawdust goes... Old Smokey's gonna be paying a visit 😅

[@rkalle66]

I was hand scraping a aluminium dove tail rail with the (sharp) side edge of my chisel. The precision was at least equal to filing. The finish was better.

[@vileguile4]

I fed my bandsaw with 3mm stainless steel and the morning after the tooth fairy had visited it :)

[@AhmetCnarOzuneUyans]

I did made similar metal pieces (from steel or iron or aluminum) and I don't have any fancy metal tools either. I did use an angle grinder to cut the rough shape ( a metal hacksaw can be used also) then clean and straighten the side with files. If you use guiding blocks and have good files, the sides and edges will be very smooth and straight... For the inside parts, I first drill holes with drill bits for metal, then clean again carefully via files... It is important to cut or drill always wider then the lines, so that you can clean with files. So, basically: 1)angle grinder + 2)hacksaw + 3)files + 4)drill bits for metal are very enough to do so many things with metal. You can even shape spring steel with this tools. Patience is required plus good drill bits... With cheap drill bits, it is almost impossible to drill steel. (I don't even have a drill press! I drill with a hand drill)

[@muellermade4857]

what are guiding blocks?

[@AhmetCnarOzuneUyans]

@@muellermade4857 I just clamp a straight edged, 90 degree wooden piece to the metal piece, where I want metal piece to be straight. That I called a guiding block. When I file the metal and when the file starts to file the wood block piece, then I stop there.

[@castletown999]

Be very careful if you have a dust extraction system. Hot metal particles can ignite in the air stream and start a fire in the sawdust in the filter. Yes aluminum does burn. In fact, it is an ingredient in some explosives.

[@waveoflight]

I'm looking forward to your camera build.

[@AH900112]

Wow, exactly what I needed. I have been searching for slow speed band saws that dont cost a fortune. What is your opinion of the new "Pégas Scroll Band Saw"? What is the pros and cons if one wishes to work much in thin brass/aluminium but occasionally make small projects in hard woods? Is it nearly impossible to make effortless long straight cuts in wood and soft metals with this scroll band saw you think?

[@dolfinmagikpro]

Great video and wonderful information! Though I have not tried it myself, I have heard that turning the table saw blade backward will help minimize catching and the issues that you mentioned. Just curious if you have tried metal working using a wood lathe. Would love to see how that would work out! Thank again! Have a better day!

[@spamdump4459]

Learned a lot. But my major take away is going to be the addition of the term "damp underwear" to my lexicon. There's a lot packed into that phrase.

[@AlainPilon]

I guess a spiral bit would vibrate much less than the straight bit

[@peterfitzpatrick7032]

When cutting slots in metal, you will get swarf lodging in the slot & you will end up "re-cutting" the chips... not good... Aluminium is also prone to causing built-up edge on the cutter which changes the cutting parameters...a spray of wd40 helps here... Brass needs to be machined with 0° rake or even negative rake... positive rake on a cutter/blade in brass will pull the cutter into the material... kinda like when you route in the "wrong"direction... Also don't forget, woodworking machines aren't built nearly as rigid as metalworking machines.... for a reason... take yer time and no "big bites" You are correct, cutting metal using woodworking cutters/equipment is possible... but a knowledge of the different forces involved is going to make for more successful & SAFE machining...

[@paulwyleciol3459]

10:43 makes me angry und then speaking about safety and your fingers. But your post was so interesting so you get a thumbs up anyway ;-)